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TRANSCRIPT
Cummins Onan RV Generator Review
Karl Wilson Onan Business Development Manager
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Agenda
New Branding Load Management Operation Exercising your generator Maintenance Common Issues CO Detector Service
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Literature
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www.cumminsonan.com
www.funroads.com
www.cumminsonanstore.com
Where to look for help? Cummins Onan – Internet
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CumminsOnan.com
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RV Technical Documents Available Online – www.cumminsonan.com
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Product Specifications Sheet Downloaded from www.CumminsOnan.com
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Product Operators Manuals – Handbook
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Product Owners Manual Downloaded from www.CumminsOnan.com
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RV Service Diagrams www.cumminsonan.com
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RV Service Videos www.CumminsOnan.com
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Lifestyle and Service Advice? www.funroads.com
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Need Parts or a printed manual? www.cumminsonanstore.com
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RV Handbook Review – F1123
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OBJECTIVE
TO DETERMINE HOW TO GET THE MOST ENJOYMENT FROM YOUR GENERATOR
HOW TO PREVENT GENERATOR FAILURE
BASIC SERVICE TIPS
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Important Safety Precautions for Your Generator
Do not operate the generator with a faulty exhaust system If your RV bottoms out, inspect the generator exhaust system for
damage Always disable auto start systems while refueling, servicing and
storing Never sleep with generator running unless you have a carbon
monoxide detector that is working properly Don’t store anything in the generator compartment Perform all service and maintenance work with the generator
engine off and the positive battery cable disconnected Listen for changes in sound, noise or vibration from your generator
and investigate WHY!
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#1 Issue Load Management
“Keeping the breaker from flipping”
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Load Management
Load Management is the systematic process of assuring your generator can supply the power (kW) needed to power your electrical needs
Two things make the lights go out – 1) Overloading the generator – 2) Overloading the circuit breaker(s)
What you need to know 1) Determine the ‘rating’ of your generator 2) Determine the total loads in your coach 3) Account for hidden loads 4) Understand your operating environment
Even though the breaker trips, (lights go out) the generator keeps running in many situations.
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Determine the rating of your generator
Look at the amps nameplate on your generator
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Determine the rating of your system
Every generator has circuit breakers that may limit the current below the nameplate rating – 8QD is rated for 66.3 amps continuous
• Has two 30amp circuits (Double pole single throw) • Capacity of any circuit is 30amps
Every coach has a breaker panel inside as well which breaks each circuit from the generator into smaller (fewer amp) circuits
Before resetting any circuit breaker turn off and reduce loads. Generator will continue to run even if circuit breakers blow. Generator will usually only shut down on dead short, or if
operating conditions have reduced output ‘capacity’. • Look for fault code
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Determining Your Load Capability
Estimate the total watts of electrical products that are typically in use at the same time. For example: Air conditioner 1920 watts 120V x 16A Battery charger 2520 watts 120V x 21A Blender 600 watts 120V x 5A Total 5040 watts This number should
not exceed the output of the generator.
Conversion formula: watts = volts x amps
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Determining The Load in your Coach This is in your handbook
Average Required Approximate Appliance Wattage Amps
Air conditioner 1400-2400 9-20 Battery charger* Up to 3000 6-28 Blender 600 5.5 Broiler 1350 12 Coffee maker 550-1000 4-8 Compact disc player 50-100 0.5-0.9���
& speaker Computer 50-100 0.5-0.9 Converter 500-1000 4-8 Curling iron 20-50 0.2-0.5 Dishwasher 1400 12 Electric:���
Blanket 50-200 0.5-1.5���Broom/vacuum 200-500 1.5-4���Drill 250-750 2-6���Fan 25-100 0.2-0.9���
Average Required Approximate Appliance Wattage Amps
Electric: (cont’d) Frying pan/wok 1000-1350 8-11���Stove (per element) 350-1000 3-8���Water heater 1000-1500 8-13���Water pump 500-600 4-5
Hair dryer 350-1500 3-13 Iron 500-1200 4-10 Light bulbs 40-100 ea. 0.36-0.9 Microwave 700-1500 6-13 Radio 50-200 0.5-1.5 Refrigerator 400-1000 3-8 Sewing machine 125 1.0 Space heater 1000-1500 8-13 Television 200-600 1.5-4 Toaster 750-1200 6.5-10 Washer/dryer 2000-2250 16 VCR 150-200 1.15
Conversion formula: watts = volts x amps
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Things that effect the available power
Altitude • Altitude derates 3.5% for every 1000 ft
– Approximately 16% in Denver – Altitude adjustment on Gasoline sets – Don’t change any other settings
Temperature • Temperature derate 1% for every 10 deg F over 77 F.
Nameplate rating is set at sea level and up to 125 F. air inlet temperature
• Most will do better than rating Hidden Loads
• Motor Starting (Air Conditioner) = 3-4 x Running Watts • Battery Charging = “Invisible Load” (Page 6)
– 100 Amps DC = 2520 watts AC = 21 Amps = 11,000 AC plus a microwave.
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Load Management
Either manually or automatically – You are usually the load manager - Manual – Some coaches have load management built in
• Turns loads on and off based on total watts used
Do not forget the hidden loads – Battery Chargers can pull up to 28 amps
• Turn charge rate down when more power is needed for coach living comforts
• All modern three stage battery chargers go to Bulk charge when first turned on – Very high amps.
– Water Heaters
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Manage your Loads
Overloading a genset will cause, – Circuit Breaker tripping – Overheating – Low Voltage – High oil consumption – Decreased genset life
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Transfer Switch Transfer switch prevents shore power and generator
power from ‘mixing’
Either Manual or automatic – Most newer coaches are automatic – If you have to plug your shore power cord into a box, this
is a manual system, common on some Class C and Towables
It is perfectly fine to start genset while plugged in
Shore Power is usually primary power – Depends some on Coach Manufacturer
If generator is running, breakers are on, but no power in the coach, you likely have Transfer Switch issue
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Auto Start Systems
AGS – Auto Generator Start Charge batteries at pre-determined state of discharge
– How Long to Charge (P. 7) varies with: • Allowed Discharge Point • Capacity in Amp/hrs • Quiet time settings • Battery Condition • Charge Rate • Quit Charge Setting
Air Conditioning Demand Make sure unit is in Auto before leaving
– All units have safety input and time out functions
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Disable Auto Start
Disable for Servicing of Generator or any part of the electrical system
When re-fueling Motorhome is out of use
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Starting and Stopping Procedures
Before Starting, good practice to turn off air conditioners and large electrical loads especially in cold weather – Note: Most transfer switches take care of this
Prime by holding Stop (All Quiet Diesels, MicroQuiets, and Marquis Golds)
To Start – Press and hold Start at the Control Panel or at the Set – Quiet Diesel: Auto pre-heat flash, then crank/start – Don’t Over-Crank with no start…. 20 seconds/then 2 minutes
wait Let the Generator warm up before applying loads To Stop – Press Stop (Do not need to hold down)
– Good practice to remove loads and let generator run for 3-5 minutes before stopping.
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Preventing OVER 70% of Service Issue
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Exercising your Generator
Minimum of 2 hours every month @ 50% load – Up to full rated load if practical
• Use space heaters to apply loads (1500W each) • BE SAFE
Why is this necessary? – Lubrication and expel moisture – Helps avoid fuel varnishing in the carburetor – Uses full range of generator system
Run AC while traveling What if I don’t?
– Increased service issues – Poor performance – Not starting – Inability to run loads in coach – Upset spouse (because I told you to)
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ROUTINE MAINTENANCE
Refer to your Operators Manual or P. 15 in Handbook Oil Change:
– MicroLite/MicroQuiet & Camp Power • First time = 20 hours and then every 150 hours or once a year.
– Marquis Gold • First time = 50 hours and then every 150 hours or once a year.
– Quiet Diesel • First time = 50 hours and then every 150-250 hours depending on
model or once a year Air / Fuel Filters: 450-500 hours Coolant: 50/50 blend every 2 years Spark Plugs: every 500 hours
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Maintenance intervals may need to be shortened if: – You are operating in high ambient temps – You are operating at extended high loads – You are operating in a dusty environment – You level your motorhome, and bring the genset closer to
the ground
Bring Spare filters – They can spoil a trip
• Oil, Air, Fuel, and fan belt
MAINTENANCE INTERVALS ARE ONLY GUIDELINES
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MAINTENANCE INTERVALS ARE ONLY GUIDELINES
Air Cleaner Caused shut down at 50 hours of use.
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Onan 4.0 Microquiet
Onan Marquis Gold
Generator Models
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Onan 5.5 Quiet Diesel
Onan 7.5/8.0 Quiet Diesel
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Onan 10 &12 Quiet Diesel
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Marquis Platinum™ / Marquis Gold™
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MicroQuiet™
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Quiet Diesel™ 5500
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Quiet Diesel™ 7500/8000
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Quiet Diesel™ 10000/12500
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Oil
Reference Page 24 in Handbook for correct Ratings and Viscosity Grades
Check level daily or every 8 hours of operating time Synthetic oil
– Okay on Cummins Onan generators after initial break-in but do not extend the published oil change intervals
Fill level – KV/KVD/KVC = Do not screw in the Dipstick – Balance = Screw in the Dipstick
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Oil Capacities – Gas & LP
Model Quarts
KV/KVD - MicroLite 1
KY/KYD - MircoQuiet 1.6
HGJAB – Marquis Gold 2
HGJAA – Marquis Platinum 2
HGJAC – Emerald Advantage 2
BGE - Emerald 3.5
BGM - Marquis 3.5
NHE - Emerald 3.5
NHM - Marquis 3.5
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Oil Capacities – Diesel
Model Quarts
HDKBA - 5500 Quiet Diesel 2
HDKAH\J\K – 6000\7500\8000 Quiet Diesel 3
HDKCA\B – 10,000\12,500 Quiet Diesel 5.9
HDCAA\B - 10,000\12,500 Quiet Diesel 6.7
HDKAG 5
DKC 4
DKD 4
DKG 5
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Fuel
Reference Page 23 in Handbook Gasoline
– No more than 10% ethanol – Not more than 5% methanol – E-85 is not approved!
Stabilizers – OnaFresh
LP - Clean HD-5 grade liquid propane gas in a mixture of at least 90% propane – Vapor – Liquid Withdrawl
Diesel – ASTM-2-D or ASTM -1 D < 32F with min Cetane of 45 – Bio-diesel up to 5%. – Low Sulfur Diesel is OK for all QD product
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Coolant
Recommend 50/50 mix of ethylene glycol coolant Kubota does not recommend propylene glycol
coolant – Heat Rejection Kubota does not recommend use any rust inhibitor
or additives Replace the coolant every two years. Clean soft water
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Coolant Capacities
Model Quarts
HDKBA - 5500 Quiet Diesel 2.5
HDKAH\J\K – 6000\7500\8000 Quiet Diesel 4.2
HDKCA\B – 10,000\12,500 Quiet Diesel 6.6
HDCAA\B - 10,000\12,500 Quiet Diesel 6.1
HDKAG 5
DKC 4
DKD 4
DKG 4.5
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Lubrication
Only where the manual indicates Oil attracts dirt Do not lubricate the grommets on the Marquis
Gold door
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Exhaust Extension Systems
Onan does not recommend any modifications to the exhaust system
Potential issues with Vertical Extensions – Damage to generator exhaust system – Excessive back pressure – Safety if roof vents are open
Improper installation can create a safety hazard. Tailpipe / Exhaust should have no load placed
on pipe, and must be free to ‘shake’
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CO Detectors
Take them seriously Make sure they work
– Some have expiration dates One can have a CO issue even if your engine or
generator isn’t running Reference Page 12 in Handbook for this and
other safety precautions
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Cooling
All Cummins Onan generators require fresh cool air to run.
The area under and around the genset should be left clean and unobstructed.
Do not dig a hole to level the coach.
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FAQ
Pages 56-62 in Handbook Does my generator charge my batteries?
– Not directly Why does my generator stop at ~1/4 tank of
fuel?
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Common Concerns
Replacement Manuals? – www.cumminsonan.com
• Download operators and parts (Adobe .pdf) – www.funroads.com - purchase hard copy
Owner’s Handbook – www.cumminsonan.com – Local Onan Dealer or Distributor
Replacement – Service Parts – Dealer/Distributor directory – www.funroads.com – Green Label Parts
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In Need of Service?
Maintenance parts on Handbook pages 30-33 Nameplate Information
Model/Spec/Serial Number (Example: 4KYFA26100K / D020356577
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QD Nameplate
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Model Number
Model Number 4KYFA26100K – 4 – kW Rated Output – KY – Model Designation – FA – Fuel / Engine Type – 26100 – Model Number – K - Spec Letter
Serial Number D020356577 – D - Month of Factory build (A= January) – 02 - Year of Factory build (02 = 2002) – 0 - Plant Code (0 = Minneapolis, MN.) – 356577 - Six Digit Sequential Serial number
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In Need of Service?
Where to Find It – Dealer Directory – Call: 1-800-888-ONAN (1-800-888-6626) – On Line: funroads.com, cumminsonan.com,
Give fault code to service location
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Common Service Issues
Most Common – Engine Oil Level – Battery Connections - Clean & Tight – Watching the Fuel Gauge – Not Overloading the Generator – Gasoline storage/stabilization
LP Mud Doppers in the LP Regulator vent line. High pitch or rattling on 7500/8000 Quiet Diesel Loose
air cleaner cover. Broken flex coupling/exhaust elbows due to improper
exhaust components
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Reading Fault Codes: MicroQuiet
Reference Operators Manual Read at Start/Stop Indicator Light Three Blinks = Service Fault
– Press STOP once to see secondary code – Two digit code 1,2,3, or 4 blinks, a brief pause and then 1-9
blinks • blink-blink-blink – pause -- blink-blink-blink-blink-blink-blink = Fault
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within 5 seconds. Last fault will be displayed even if the condition that caused the shutdown has been corrected.
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Reading Fault Codes: Marquis Gold
Reference Operators Manual Read at Start/Stop Indicator Light Two Blinks = shut down on low oil pressure Three Blinks = Service Fault
– Press STOP once to see secondary code – Two digit code 1,2,3, 4 or 5 blinks, a brief pause and then 1-9
blinks Four Blinks = Exceeded Crank Time Restoring Fault Code Blinking by pressing STOP 3 times
within 5 seconds. Last fault will be displayed even if the condition that caused the shutdown has been corrected.
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Reading Fault Codes: Quiet Diesel
Reference Operators Manual Read at Start/Stop Indicator Light One Blink = Shut down due to High Temperature Two Blinks = Shut down on low oil pressure Three Blinks = Service Fault
– Press STOP once to see secondary code – Two digit code 1,2,3, or 4 blinks, a brief pause and then 1-9
blinks Restoring Fault Code Blinking by pressing STOP 3 times
within 5 seconds. Last fault will be displayed even if the condition that caused the shutdown has been corrected.
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Onan Warranty
Warranty Start Date – The day the set was purchased by its original owner.
3 Years or 2,000 hours 90 Days Adjustments Available 5 Year Warranty What is not covered?
– Problems caused by improper maintenance or misuse of the generator even if they occur during the warranty period. Example: Carburetor varnishing.
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Summary
Load Management Operation Exercising your generator Maintenance Common Issues CO Detector Service
Frequently Asked Questions
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Common Questions
Why does my 7.5 QD only have one 30amp breaker? – Why does it keep blowing?
Should I exercise my generator?
What is my maintenance interval?
Is it O.K. to use synthetic oil?
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Generator Operation -
Q: Once the generator is started, should it continue to run for a certain length of time?
A: Ideally, Onan Gensets should run for a minimum of 30 minutes to give them a chance to warm up. Once warmed up, running your generator for five-minute intervals should be fine. Remember to turn on some appliances so the generator works while it’s running. Running it for more than 30 minutes at no load only burns fuel unnecessarily and adds costly maintenance.
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Q: Is it practical to power the roof air conditioner with my generator while traveling on the road?
A: Yes, that is what a generator is for, portable electrical power. In fact, it can help you economize on your vehicle fuel because the generator uses less fuel. Plus, it gives you an opportunity to exercise your generator. Any appliance that can be run in a stationary position can also be powered while driving.
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Q: Can I run an RV generator in a National Park?
A: Onan MicroLite™ and Quiet Diesel™ Gensets, uninstalled, are quieter than National Park sound level requirements. (Most parks have quiet time between the hours of 10PM and 7AM.) When installed, Marquis models are also quieter than park standards. Laboratory tests show they measure well below the park standard of 60 dB(A) at 50 ft. For comparison, normal room conversation is typically 62 dB(A).
YOUR QUESTIONS?
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